Payload User's Guide - Free Flyer 1

Version 0.2 Pre-release

• Aspects of this guide are subject to change
• For more information, please contact through the mission request form

Table of Contents

1. Introduction
2. Mission Overview
3. Payload Accommodations & Environments
4. Electrical & Data Interfaces
5. Payload Design & Verification Requirements
6. Integration & Mission Operations

1.0 Introduction

1.1 Purpose of this Guide

This guide provides payloads with the necessary information to design, qualify, and integrate their payloads for missions on the Free Flyer 1 modular reentry system.

1.2 Vehicle Overview

Free Flyer 1 is a modular reentry system designed to be launch vehicle agnostic, perform on-orbit operations, and precisely return payloads to Earth. Its modular design allows for rapid integration of diverse payloads, from microgravity experiments to technology demonstrations.

1.3 Mission Concept

A typical mission consists of:

1. Launch: Integration with a launch vehicle (e.g., Falcon 9).
   • Payload off
2. On-Orbit Phase: Deployment from the launch vehicle and on-orbit operations for as short as 5 days and up to 180 days.
   • Payload on
3. Reentry: Autonomous de-orbit burn, hypersonic reentry, and parachute deploy.
   • Payload off (payload power during reentry available upon request)
4. Recovery: Parachute-assisted soft landing at a pre-designated land-based recovery zone or water landing and rapid recovery by ship.
   • Payload off

2.0 Mission Overview

2.1 Standard Mission Profile

• Launch-to-Deployment: Typically less than 30 minutes
• On-Orbit Duration: Up to 180 days
• De-orbit to Landing: Typically less than 30 minutes
• Recovery Access: Payload recovery within L + 6 hours

3.0 Payload Accommodations & Environments

3.1 Payload Volume & Mass

• Standard Payload Envelope: 50 x 30 x 60 cm
• Maximum Payload Mass: 30 kg
• Center of Gravity (CG): TBD

3.2 Mechanical Interface

• Interface Options:
  1. Preloaded tabs
  2. Mounting Rails
  3. M6 fasteners

3.3 Dynamic Environments

The payload must be designed to withstand all ground and flight environments. The values below are preliminary and will be finalized per mission.

• Quasi-Static Loads:
  • Qualification
    • In Plane: 20 G, Sine Sweep 20-100Hz
    • Out of Plane: 25 G, Sine Sweep, 20-100 Hz
  • For Payloads with a primary resonant frequency < 200 Hz, please reach out
• Random Vibration:
  • Qualification: 14.1 GRMS
    • 3 min/axis
  • Acceptance: 10 GRMS
    • 1 min/axis

3.4 Reentry Environments

This section defines the unique environments during the reentry phase, which are often the driving design case.

• Reentry Deceleration Loads: The QSL values in 3.3 include reentry. The peak deceleration is approximately 7 g.
• Venting: Payloads which are not hermetically sealed must be designed to vent to prevent pressure differentials. The max external pressure rate of change is 1 psi/sec.

3.5 Thermal Environments

• On-Orbit:
  • 100 W Payload Power
    • Interface Temperature (Payload Off): [-20°C to +30°C]
    • Interface Temperature (Payload On): [+50°C +/- 10 °C]
  • 10 W Payload Power
    • Interface Temperature (Payload Off): [-20°C to +30°C]
    • Interface Temperature (Payload On): [+4°C +/- 2°C]
      • Higher payload interface temperatures available upon request up to 40 C
• Reentry Thermal:
  • The payload is protected by the vehicle's Thermal Protection System (TPS).
  • Max Interface Temperature (Reentry): The payload interface plate will not exceed 40°C during reentry, with a duration of 15 minutes.
• Thermal Model: A simplified vehicle thermal model is available upon request to assist in payload design.

3.6 Contamination Control

• Cleanliness: Payloads shall be delivered meeting ISO 8 (Class 100,000) cleanliness standards.
• Outgassing: Materials which are not hermetically sealed must meet ASTM E595 requirements:
  • Total Mass Loss (TML): ≤ 1.0%
  • Collected Volatile Condensable Material (CVCM): ≤ 0.1%

4.0 Electrical & Data Interfaces

4.1 Power Interface

• Available Power: up to 100 W, continuous
• Bus Voltage: 28 ± 6 VDC, unregulated
  • Regulated voltage available upon request
• Max Current: 10 A peak for short durations
• Connectors: Vehicle provides One (1) 9-pin D-sub connector for payload power and One (1) 15-pin D-sub connector for communications.
• Grounding: Grounding is provided through the connector and payload mounting interface

4.2 Data Interface

• Commanding and Telemetry:
  • RS-422, Asynchronous
  • Data Rate: Up to 1 Mbps to flight computer
  • Additional interfaces available upon request
• On-Board Data Storage: The vehicle provides 10 GB of on-board storage for payload data..
• Connectors: Vehicle provides One (1) 15-pin D-sub connector for payload power and communications.

4.3 Communications

• TTC: Up to 10 Mbps downlink available for payload telemetry
• RF Blackout: Live communication to/from the vehicle to ground terminals will be unavailable during reentry for approximately 15 minutes.
• Payload RF Systems: Any payload-provided transmitters must be declared and approved. Frequencies must be coordinated with Dispatch and spectrum authorities.

5.0 Payload Design & Verification Requirements

5.1 Structural Design

• Factors of Safety: Payloads must meet the following factors of safety (FOS):
  • Yield: 1.25
  • Ultimate: 1.50
• Analysis: A structural analysis report is required for verification.

5.2 Safety & Mission Assurance

• Inhibits: All hazardous functions (e.g. high-voltage, high pressure) must be protected by a minimum of two (2) independent inhibits.

5.3 Verification & Testing

Payloads must be subjected to an acceptance program that includes:

• Functional Test: Ambient conditions
• Vibration Test: NASA GEVS
• Thermal Vacuum Test: 5°C beyond on orbit conditions, payload on
• Proto-qualification: New designs must be tested to qualification levels Payload acceptance testing may be provided by Dispatch upon request

6.0 Integration & Mission Operations

6.1 Integration Flow

• L-210 Days: Payload PDR, Interface Control Document (ICD) preliminary.
• L-180 Days: Payload CDR, ICD final.
• L-60 Days: Payload delivery to Dispatch integration facility.
  • Payload integration with vehicle interface checks.
• L-30 Days: Vehicle environmental testing complete.
• L-15 Days: Integration with Launch Vehicle.

6.2 Pre-Launch & Launch Ops

• Payload Access: Latest payload access is 24 hours prior to launch vehicle integration.
• Launch Command: Payload is powered off from launch vehicle integration to separation on orbit.

6.3 Recovery Operations

• Timeline: Recovery team will be on-site within L+4 hours
• Payload Access: Payload module will be removed and transferred to a controlled environment within L+6 hours.
• Handover: Payload will be handed back to the customer. Dispatch can provide data retrieval and cold-stowage services if required.